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DC series Cyclone Separators

Up to 98% Condensate Separation Efficiency

For Steam and Air

Overview

Remove water droplets entrained in steam or air with TLV's DC series steam separators and air separators.

The DC cyclone separators can be installed on steam lines, air lines, and at the inlet side of equipment to enable removal of virtually all water droplets within the flow. This can significantly improve heat quality, preventing problems such as:

  • Low Heating Efficiency
  • Product Defects or Off-spec
  • Erosion of piping or valve parts, and other related problems

Condensate Separation

Why a Separator is Necessary

Drip legs are designed to remove a considerable portion of the condensate flowing through piping – that which has fallen out of the steam or air flow, but cannot remove the water droplets entrained within the flow itself.


Entrained condensate is not all discharged

Steam Separators and Air Separators - DC Series
Drip legs alone cannot discharge all water droplets entrained within the steam or air.

These droplets may lead to problems such as erosion of valve parts and piping from liquid droplet impingement (LDI) and product defects from water droplets creating cold spots on steam heating surfaces or actually coming in direct contact with the product. In steam heating processes, the thickness of the water film significantly reduces heating, so removing as much water as possible will provide a more effective overall improvement.


Cut-view of Condensate Discharge Through Drip Leg

Steam Separators and Air Separators - DC Series
Water droplets entrained in steam will be carried over and pass by the drip leg because of the speed at which steam/air flows through piping.

Negative Impact of Condensate Droplets in Steam Processes

Elbow in Piping

Water droplets may lead to the formation of pin holes from LDI erosion at elbows in the piping.

Direct Heating Application

Water droplets may cause product defects when coming in direct contact with the product being heated, or reduce heating quality / efficiency when contacting heat transfer surfaces.

Negative Impact of Condensate Droplets in Air Processes

Air Blowers

Water droplets in a compressed air line may cause product defects when the droplets come in contact with the product.

Pneumatic Cylinders

Water droplets in air cylinders can affect the movement of pistons or cause damage to other parts, which may lead to the breakdown of equipment.

Features

DC Series Separator Features

Cyclone Separator

The DC series separators use a cyclone separator to separate and remove water droplets from steam and air with 98% efficiency. High velocity centrifugal force and directional changes are key factors that enable such a high degree of separation.

Built-in Free Float® Trap

The Free Float® enables continuous discharge of condensate while still keeping a steam-tight / air-tight seal. This rapid discharge design with no back-up is essential to prevent condensate from being re-entrained into the steam or air flow.

Cut-view of DC Series Separator

Droplets entrained within the flow are driven by high velocity towards the bottom of the separator through centrifugal force and abrupt directional change, then are discharged through the built-in steam trap.

Separating Condensate from Steam/Air

DC Series: Up to 98% Separation Efficiency

Steam Separators and Air Separators - DC Series
Condensate entrained in steam is mechanically removed using a steam separator.

Effect of Flow Rate on Separation Efficiency

The separator is designed to prevent droplets from returning back into the flow of steam or air and instead be discharged through a built-in trap. This enables up to 98% separation efficiency (steam flow = 30 m/s [100 ft/s]).

Sample Calculation: Steam Dryness Improvement of 10% Wet Steam at 10 barg (145 psig)

When calculated, the increase in steam dryness is quite significant, reaching up to 99.8% steam dryness as shown in the sample calculation below:

  • Total Latent Heat of 10% Wet Steam = 1999 kJ/kg · 0.9 = 1799 kJ/kg [860 BTU/lb · 0.9 = 774 BTU/lb]
  • 10% Wetness Loss = 200 kJ/kg [86 BTU/lb]
  • Removing 98% of Wetness = 1799 kJ/kg + (200 kJ/kg · 0.98) = 1995 kJ/kg [774 BTU/lb · (86 BTU/lb · 0.98) = 858 BTU/lb]
  • Improved Steam Dryness = 99.8% (1995 kJ/kg / 1999 kJ/kg [858 BTU/lb / 860 BTU/lb])

Key Points:

  • Heating Efficiency Improved / Time Reduced
  • Cold Spots Removed / Heating Quality Improved

For additional Information about Dry Steam, please read:

Applications

For Steam Applications

  • Steam distribution lines
  • Turbines
  • Steam heating processes (indirect heating):
    • Reaction kettles, dryers, heat exchangers, jacketed vessels, presses, etc.
  • Steam heating processes (direct heating):
    • Steamers, cookers, cylinder dryers, kneaders, steam atomization systems, etc.

For Air Applications

  • Air distribution lines
  • Before Filtration
  • Air processes:
    • Coaters, etc.

Line-up

DC Series Line-up

Model Appearance Fluid Type Max Operating Pressure (psig) Body Material Specifications
DC3S Steam 300 Ductile Cast Iron View All View All
DC5S 230 Bronze
DC3A Air 300 Ductile Cast Iron View All View All
DC5A 150 Bronze
DC7* Steam or Air 362 Cast Stainless Steel View All View All
DC-L, DC-LS, DC-LUS* 550 Carbon Steel

* Require a separate steam trap.